Investigation of the Laser Powder Bed Fusion Process of Ti-6.5Al-3.5Mo-1.5Zr-0.3Si Alloy

Abstract Laser powder bed fusion (LPBF) is an advanced manufacturing technology; however, inappropriate LPBF process parameters may cause printing defects in materials. In the present work, the LPBF process of Ti-6.5Al-3.5Mo-1.5Zr-0.3Si alloy was investigated by a two-step optimization approach. Subsequently, heat transfer and liquid flow behaviors during LPBF were simulated by a well-tested phenomenological model, and the defect formation mechanisms in the as-fabricated alloy were discussed. The optimized process parameters for LPBF were detected as laser power changed from 195 W to 210 W, with scanning speed of 1250 mm/s. The LPBF process was divided into a laser irradiation stage, a spreading flow stage, and a solidification stage. The morphologies and defects of deposited tracks were affected by liquid flow behavior caused by rapid cooling rates. The findings of this research can provide valuable support for printing defect-free metal components.